Blind and shade cutting center with movable cutting station

ABSTRACT

An apparatus for sizing a window covering in a retail outlet includes a housing having a first end and a second end, and a top operating surface adapted to support a window covering to be sized. Movably disposed at the first end of the housing is a first cutting station that includes a stationary die and a movable die. The stationary die and the movable die are adapted to receive and size a window covering. The first cutting station further has a top portion and is movable from a first operating position to size a window covering to a retracted position in which the top portion is substantially flush with or lower than the top operating surface.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of and claims priority toU.S. Ser. No. 09/911,292, filed on Jul. 23, 2001, now U.S. Pat. No.6,604,443.

FIELD OF THE DISCLOSURE

The present invention relates generally to the field of window coveringsizing machines and more particularly to a blind and shade cuttingcenter.

BACKGROUND OF THE DISCLOSURE

Mass retail merchandisers sell a large number of window coveringsdirectly to consumers. Standard sized window coverings are sized to aconsumer's specifications while the consumer waits. The apparatusemployed to size the various window coverings must be both easy to useby an employee of a retail outlet and should not require an extensivetraining period.

Additionally, the floor space that the cutting apparatus requires shouldfit within the existing structure and layout of the retail outlet.Further, the cutting apparatus ideally should size a number of differenttypes of window coverings, such as metal or vinyl mini-blinds, verticalblinds, pleated shades, and cellular shades.

Many attempts have been made to integrate various window coveringcutting mechanisms into a single multi-station system. One example of amulti-station system is disclosed in U.S. Pat. No. 5,456,149 toElsenheimer et al. entitled “Sizing System for Window Coverings” issuedOct. 10, 1995. The '149 patent discloses a station having a flip-topsurface including a pleated shade sizing station on one side and amini-blind sizing station on the other. This system minimizes the spacerequired by the merchandiser to cut various window covering products.This allows the retail outlet to include other stock and products inspace otherwise occupied by various window covering sizing equipment.

Recently, more retail merchandisers utilize 8-foot bay spacing todisplay and sell products. Accordingly, a shade and blind cutting centerthat can be located within the 8-foot bay environment is needed.

The sale of vertical blind products has also increased through massmerchandiser retail outlets, requiring the ability to size not only thewidth of the vertical blind head rail but also the length of thevertical blind slats. However, if a cutting apparatus is to be locatedwithin an 8-foot bay environment, any vertical blind slat extendinggreater than 8 feet would not be able to be sized with an apparatuslocated within the 8-foot bay. Accordingly, there is a need for avertical blind cutting apparatus that would fit within the 8-foot bayenvironment as well as be able to size vertical blind slat producthaving a length greater than 8 feet.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingdrawings.

FIG. 1 is a perspective view of the apparatus located in a bay in astored position.

FIG. 2 is a perspective view of the cutting apparatus of FIG. 1 in anoperating position.

FIG. 3 is a cross-sectional view of the apparatus taken generally alonglines 3—3 of FIG. 1.

FIG. 4 is a top plan view of the apparatus of FIG. 2.

FIG. 5 is a top partial view of the area taken generally along lines 5—5of FIG. 4.

FIG. 6 is a cross-sectional view of the locator pin taken generallyalong lines 6—6 of FIG. 5.

FIG. 7 is a cross-sectional view of the die assembly of the firstcutting station taken generally along lines 7—7 of FIG. 4.

FIG. 8 is a cross-sectional view of the die and blade mechanism of thefirst cutting apparatus taken generally along lines 8—8 of FIG. 4.

FIG. 9 is the die and blade portion of the first cutting apparatus ofFIG. 8 in the fully extended cutting position.

FIG. 10 is a cross-sectional view of the blade and die apparatus of FIG.8 taken generally along lines 10—10 of FIG. 8.

FIG. 11 is a cross-sectional view of the cutting mechanism takengenerally along lines 11—11 of FIG. 8.

FIG. 12 is a cross-sectional view of the second cutting station takengenerally along lines 12—12 of FIG. 4.

FIG. 13 is a view of the head rail cutting mechanism with the die in theraised position.

FIG. 14 is a view of the head rail cutting mechanism die cutter in theraised position with the punch mechanism fully extended.

FIG. 15 is a cross-sectional view of the cutting apparatus takengenerally along lines 15—15 of FIG. 12.

FIG. 16 is a cross-sectional view of the cutting mechanism takengenerally along lines 16—16 of FIG. 12 in the extended cutting position.

FIG. 17 is a cross-sectional view of the apparatus taken generally alonglines 17—17 of FIG. 4.

FIG. 18 is a partial cross-sectional view of the first cutting stationin the lower position.

FIG. 19 is a cross-sectional view taken generally along lines of 19—19of FIG. 18.

FIG. 20 is an exploded perspective view of three locators, rail andscale.

FIG. 21 is a cross-sectional view of the apparatus of FIG. 20.

FIG. 22 is an exploded perspective view of the connector clip and headrail aperture.

FIG. 23 is an exploded perspective view of the connector clip of FIG. 22attached to the head rail aperture, and a portion of the locator.

FIG. 24 is a top partial view of the head rail and connector clippositioned by the locator.

FIG. 25 is a top plan view of the cellular blind head rail and bottomrail positioned in the first cutting station of FIG. 7.

FIG. 26 is a top plan view of the cellular blind shade materialpositioned in the first cutting station of FIG. 7.

FIG. 27 is a cross-sectional view of the measuring device extension.

FIG. 28 is a perspective view of the vertical slat clamp and woodenblind clamp.

FIG. 29 is a partial side view of the wooden blind clamp.

FIG. 30 is a partial cross-sectional view of the vertical slat clamp.

DETAILED DESCRIPTION

Referring now to the drawings, an apparatus for sizing both blinds andshades for window coverings is generally illustrated in FIG. 1. Theblind and shade cutting center 10 is slidably movable on rails 12 in andout of a bay 14. The cutting center 10 includes a first cutting station16 for sizing mini-blinds, pleated shades, and cellular shades. Thecutting center further includes a second cutting station 18 for sizingwooden blinds and vertical blinds. The first and second cutting stations16, 18 are supported by and located on opposing ends of a housing 20. Acontroller mechanism 22 allows an operator to gain access and to controlthe first and second cutting stations 16, 18. Further, cutting center 10includes a center locating and measuring system 24 to position theblinds and shades to be sized.

Referring to FIGS. 2 and 17 the housing 20 of the cutting center 10includes a bottom 26, a front wall 28, a first and second side wall 30,32, a rear wall 34, and a top working surface 36. For purposes of thisapplication the cross housing direction is defined as the direction thatis perpendicular to the front wall 28 and rear wall 34. Similarly, thelongitudinal direction will be defined as the direction that isperpendicular to the first and second side walls 30, 32. The right sideof the housing 20 will be defined from the perspective of an operator asthey face the bay 14. Accordingly, the first side wall 30 is on theright side of the housing, while the second side wall 32 is on the leftside of the housing. The longitudinal axis of the housing will bedefined as an axis extending centrally on the top working surface 36 andperpendicular to the first and second side walls 30, 32. The crosscenter axis will be defined as an axis extending centrally on the topworking surface 36 and parallel with the cross housing direction. Thecross center axis is perpendicular to the longitudinal axis.

Housing 20 may be moved from a stored position (as illustrated inFIG. 1) in which the housing 20 is located within the bay 14 to anoperating position (as illustrated in FIG. 2) in which the housing 20 islocated substantially outside of the bay 14. The stored position permitsthe housing to be completely out of the aisle of a retail or massmerchandising outlet. In the operating position, the housing isaccessible for an operator to size a blind or shade product as will bedescribed below. While it is possible to size a blind or shade productwhile the housing is in the stored position, the length of the productto be sized may be limited by the size of the bay.

The bay 14 typically includes a front surface 38 and a first and secondside support 40,42. The supports 40, 42 may be in the form of a wall ormay be in the form of a frame. When the housing 20 is in the storedposition, the front wall 28 may be flush with the front surface 38 ofthe bay 14 or maybe located a distance within the bay 14 from the aisleto ensure that no part of the cutting center 10 protrudes into theaisle. Further, if the cutting center 10 is completely located withinthe bay 14, the possibility of being damaged by a forklift or customercarts is minimized.

Housing 20 may include a handle or handles (not depicted) to facilitatesliding the cutting center 10 in and out of the bay 14 on the rails 12.All of the equipment employed in center 10 is attached to the housing20. The only portion of the center 10 that extends outward from thehousing 20 is a vacuum bag 44 of a vacuum 46 (See FIG. 3). The depth ofthe housing 20 as measured in the cross housing direction is less thanthe depth of the bay 14. This permits the vacuum bag 44 to be situatedbehind the housing 20 when the center 10 is in the stored position. Ofcourse the vacuum bag 44 could also be stored inside of the housing 20and accessed through the rear wall 34 by an access means such as a door.

As will be described below, the preferred embodiment includes a centerlocating and measuring system as well as an end locating and measuringsystem. Both systems allow the operator to size a blind or shade byreferring to only the customer's specification of the final size andlength of the blind. In contrast, other sizing methods required theoperator to calculate the amount of material to be removed from eachside of the blind and to locate the blind relative to the sizing stationaccordingly. This may lead to errors in the final product, resulting inboth scrap material as well as a delay in the time it takes to deliver afinal sized product to the consumer.

The center locating system positively locates the center of the blind tobe sized, while the end locating system locates the shade relative toone end of the shade. Where the lift cords are visible to the consumersuch as in a Venetian blind or a pleated shade it is important that thelift cords remain symmetrical about the center of the blind. The centerlocating system employs a half scale that permits an employee to sizethe blind by referring to only the customer's final width of the blind.In contrast, the end locating system may be used for cellular shadeswhere the lift cords are hidden from view and it does not matter thatthe lift cords are not symmetric about the center of the shade.Similarly, the end locating system may be used for a vertical blind headrail and vanes where the products may be sized from a single end.

Referring to FIGS. 4 and 20, the pin locator 48, the center clip locator50, and the end locator 52 are illustrated. Each locator 48, 50, 52 isattached to a respective carriage 54 having a plurality of rollers 56that are slidably received in a rail 58. The rail 58 extends proximatethe front wall 28 of the housing 20 and parallel to the longitudinalaxis of the housing 20. The rail 58 and carriage 54 device is availablecommercially and marketed under the trade mark Redi Rail™. The pinlocator 48 and the center clip locator 50 illustrated in FIG. 20 arecenter locating devices that positively locate the center of the blindor shade to be sized. The end locator 52 is a locating device that isused to both square the blind or shade and to locate certain blind andshade products relative to one end of the blind.

The pin locator 48 and the center clip locator 50 both permit a blind tobe sized from its center by engaging a center portion of the blind. Thepin locator 48 includes an extension member 60 attached to the carriage.A pointer 68 is attached to the carriage 54 and indicates the positionof the pin locator 48 relative to the first or second cutting stations16, 18 by use of a scale as discussed below. The extension 60 extends inthe cross housing direction from the carriage 54 toward the rear of thetop working surface 36. A first pin 62 extends from the carriage 54parallel with the top working surface 36 of the housing 20 and towardsthe rear wall 34. The first pin 62 is located a predetermined distanceabove the top working surface 36. A second pin 64 may extend from therear portion 66 of the extension 60 toward the front wall 28 apredetermined distance above the top working surface 36.

Pins 62 and 64 each have a cross section that corresponds to the crosssection of an aperture in the bottom rail of the shade or blind. In theexample illustrated in FIG. 6, the pin 62 has a cross shaped crosssection. However, any other shape may be employed as well, for example around cross section may be used. Pin locator 48 includes a pointer 68that identifies the location of the pins 62, 64 relative to the firstscale 70.

The center clip locator 50 is illustrated in FIGS. 4 and 20. The centerclip locator 50 includes an extension 72 attached to the carriage 54 forslidable movement in the rail 58. A pointer 74 is attached to the centerclip locator 50 that identifies the position of the locator relative toa second scale 76. The extension 72 of the center clip locator 50includes a slot 78 having a width configured to receive and positivelylocate a center clip 80 attached to the center portion of the blind headrail or bottom rail (See FIG. 22.).

Referring to FIGS. 22 and 23, the center clip 80 is positively securedto a head rail 82 or bottom rail by positive location of a protrusion 84of the center clip with an aperture 86 or other locating device in thecenter of head rail 82. Alternatively, the center clip 80 could includean aperture that is positioned relative to a detent or tab located onthe head rail. Further, any other mechanical means of locating thecenter clip 80 onto the head rail may be employed. In the preferredembodiment the center clip 80 is made of a resilient material such thatthe center clip 80 may simply be located in the center of the blind headrail prior to sizing and maintained in place by the spring force of thecenter clip 80.

As illustrated in FIG. 4, the pin locator 48 is positioned on the rightside of the cutting center 10 and the center clip locator 50 ispositioned on the left side of the cutting center 10. However, thisorientation is for illustration purposes only. It is possible thatcutting center 10 includes two pin locators 48 on both the right andleft sides of the cutting center or two center clip locators 50 on boththe right and left sides of the cutting center 10. Any combination oflocators 48, 50 may be employed depending on the type of locating systemthat is used to locate the actual products to be sized.

The pin locator 48 as illustrated in FIG. 4 is slidably positionedrelative to a cutting plane 88 (See FIGS. 10 and 11) of the firstcutting station 16 by the first scale 70. The first scale 70 is locatedon the right side of a raised portion 90 proximate the rail 58 (FIG.20). Similarly, the center clip locator 50 is slidably positionedrelative to the cutting plane 92 (See FIG. 15) of the second cuttingstation 18 by the second scale 76.

The first and second scales 70, 76 each include half scale indicia andextend proximate the front edge of the top working surface and parallelto the longitudinal axis. The first and second scales 70, 76 includehalf scale indicia where each unit of measurement is identified as twiceits actual distance from the cutting planes of the first and secondcutting stations respectively. For example, a distance of fifteen inches(15″) from the cutting plane 88 of the first cutting station 16 isidentified as thirty inches (30″) on the half scale indicia.

The half scale indicia allows an employee or operator to size a windowblind by only knowing the final desired width of the window blind. Thewidth of the window blind is defined as the horizontal distance betweenthe two sides of the window blind when the window blind is installedrelative to the window or opening to be covered. The height of thewindow blind is the vertical distance that the window blind or shadecovers. The term “length” as it is used in conjunction with the Venetianwindow blind head rail, slats or bottom rail will correspond to thewidth of the window blind.

Referring to FIGS. 4 and 20, end locator 52 includes an extension 94attached to carriage 54 for translation along rail 58. Extension 94extends from the carriage 54 in the cross housing direction and includesa first side 96 and a second side 98 parallel to the first side 96. Thefirst side 96 faces the first cutting station 16 while the second side98 faces the second cutting station 18. As will be described below thefirst and second sides 96, 98 of the extension 94 extend a sufficientdistance from the top support surface 36 to engage the ends of the blindor shade to be sized to help align the head rail, bottom rail and windowcovering material for sizing. Further, the first side 96 is also used tolocate the cellular shade as will be described below. End locator 52further includes a set block 100 extending from the first side 96 a setdistance toward the first cutting station 16. The end locator furtherincludes a cut out region or a depression 102 in the top portion of theextension 94 that permits a portion of the cellular window coveringmaterial of the cellular blind to extend through the extension 94 whenthe bead rail and bottom rail are being sized. The end locator ispositioned between the right and left locators, which as illustrated inFIG. 4 is the pin locator and center clip locator respectively. Ofcourse, as noted above, the right and left locators may both be pinlocators or center lip locators.

Referring to FIGS. 7-10, first cutting station 16 will be described infurther detail. First cutting station 16, includes a stationary die 104and a moveable die 106 slidably coupled to the stationary die 104. Aguiding die member 108 is secured to a first face 110 of stationary die104 to provide a plurality of beveled or flared surfaces 112 for guidingthe various bottom rails, slats and head rails of the blinds and shadesto be sized into openings in the stationary and movable dies 104, 106.

Referring to FIG. 8, the stationary die 104 includes three regions forcutting three different types of window covering products. The firstregion 114 is configured for sizing a mini-blind product having metal oraluminum slats and a metal head rail and bottom rail. This mini-blindproduct will be referred to as the metal mini-blind product. Firstregion 114 of the stationary die 104 includes a first channel 116 forreceiving a bottom rail of a mini-blind product, and an opening 118 forreceiving a plurality of metal or aluminum slats from the metalmini-blind product. Further, first region 114 of stationary die 104 alsoincludes a second channel 120 for receiving the head rail of the metalmini-blind product.

Additionally, stationary die 104 includes a second region 122 for sizinga mini-blind having a plurality of vinyl slats. This mini-blindconfiguration will be referred to as a vinyl mini-blind product. Thissecond region includes a channel 124 for receiving the bottom rail of avinyl mini-blind product having vinyl slats and a second opening 126 forreceiving the vinyl slats, and finally a third channel 128 for receivingthe head rail of the vinyl mini-blind product.

The third region 130 of stationary die 104 is for sizing a pleated orcellular shade and includes a first pair of channels 132, 134 forreceiving the ends of a head rail and bottom rail from a pleated orcellular shade. Similarly, third region 130 may include a second pair ofchannels 136, 138 for receiving the second ends of the head rail andbottom rail from a pleated or cellular shade, when the head rail andbottom rail are not symmetric. However, in the preferred embodiment, thehead rail and bottom rail are symmetric and therefore only a single pairof channels is required. Accordingly, the second pair of channels 136,138 is shown in phantom lines. The third region 130 also includes anopening 140 for receiving the pleated or cellular material to be sized.

Referring to FIG. 9, the movable die 106 similarly has three regionsthat correspond with the respective three regions of the stationary die104. The first region 142 of the movable die 106 includes a first dieopening 144 to receive both the portion of the bottom rail and metalslats of the metal mini-blind to be sized. A first blade 146 is attachedto the movable die 106 and separates the first die opening 144 from asecond die opening 148 that receives the portion of the head rail to besized. The first blade 146 is fastened to the movable die and includes acutting surface 150 that is proximate the stationary die 104. Firstblade 146 cuts both the metal slats and the bottom rail. The geometry ofthe first blade 146 permits the metal slats and bottom rail to be sizedwith the same blade without the blade chipping when it cuts the bottomrail member. First blade 146 has an arcuate surface that corresponds toan arcuate portion on the outer surface of the stationary die 104.However, other known cutting shapes may also be employed.

The second region 152 of the movable die 106 is located below the firstregion 142. The second region 152 includes a first opening 154 toreceive both the portion of the bottom rail and vinyl slats of a vinylmini-blind to be sized. A second blade 156 is attached to the movabledie 106 and separates the first opening 154 from a second opening 158that receives the portion of the vinyl mini-blind head rail to be sized.The second blade 156 is fastened to the movable die 106 and includes asharpened edge 160 that is proximate the stationary die 104.

The third region 162 of the movable die 106 is situated in line with thefirst region of the movable die such that it corresponds to the thirdregion 130 of the stationary die 104. The third region 162 includes afirst opening 164 and a second opening 166. A shearing portion 168 islocated proximate the first opening 164 and a shearing portion 170 islocated proximate the second opening 166. However, a single opening andshearing portion may also be used.

Finally, the third region 162 of the movable die includes a thirdopening 172 for receiving the cellular or pleated shade material to besized. A blade 174 is attached to the movable die 106 and has a bladeedge 176 to cut the cellular and pleated material as the movable die 106is moved from a retracted position illustrated in FIG. 8 to the fullyextended position illustrated in FIG. 9.

As illustrated in FIGS. 17, 18 a, and 18 b the stationary and movabledies 104, 106 are attached to a frame 178 that is movable from a firstposition in which the first regions 114, 142 and third regions 130, 162of the stationary and movable dies 104, 106 are proximate the topworking surface 36 of housing 20, to a second position in which thesecond regions 122, 152 are proximate the top working surface 36.Further the frame 178 may be moved to a third position in which theentire first cutting station 16 is lowered to a position below the topworking surface 36 to facilitate the sizing of vertical blind slatshaving a length greater than the width of the housing 20.

When the entire first cutting station 16 is lowered to a position belowthe top working surface 36, an extension scale 180 may be attached tothe housing (See FIG. 27). A vertical peg 182 fastens the extension tothe housing 20 so that the extension scale 180 remains in a planeparallel with the top working surface 36. This feature allows a simpledisassembly upon raising the first cutting station 16 and also allowsthe extension scale 180 to slip out of its position on the housing ifthe first cutting station 16 is raised without first removing theextension scale 180. Further, if the housing is moved back into the baybefore removing the extension scale 180, the scale will simply pivotabout the peg 182 to prevent damage to the extension scale 180 or to thehousing.

In the preferred embodiment, the frame is moved between the first,second and third positions with a hydraulic piston 184 that iscontrolled by the controller 22. The hydraulic piston 184 is shown inFIGS. 17, 18 a and 18 b.

In an alternative manual embodiment illustrated in FIG. 19 a pair ofspring biased release mechanisms 186 is located on either side of theframe 178 to releasably secure the frame in the first, second or thirdpositions. Each release mechanism 186 includes a spring biased button188, each having a spring member 190 biasing a pin 192 into engagementwith one of three pairs of support members 194 attached to housing 20.By manually pulling the engaged pair of buttons 188 in an outwarddirection, the pins 192 are released from the support member 194 and theframe 178 may be moved upward or downward to another one of the pair ofsupport members. In this manner, the first cutting station 16 may bemoved manually between the first, second and third positions.

The method for sizing a metal mini-blind product utilizing the cuttingcenter 10 will now be described in detail. As discussed above, cuttingcenter 10 can cut more than one type of mini-blind or shade product. Thefirst cutting station 16 includes two different regions for cutting twodifferent types of mini-blind products. The mini-blind products couldhave different geometry necessitating different die openings, and/ordifferent shearing configurations, and/or different blade combinations.In the example illustrated in the figures the first cutting station 16permits the sizing of two different mini-blind products formed ofdifferent material and having a different geometry. In the preferredembodiment, the first regions 114, 142 of the stationary and movabledies 104, 106 of the first cutting station 16 are configured to size ametal mini-blind product having a metal bottom rail, a metal head railand aluminum slats. The second regions 122, 152 are configured to size avinyl mini-blind product having vinyl slats.

A customer will measure the width of the window or windows to be coveredand bring this dimension to a retail outlet to purchase a mini-blindproduct. If the mini-blind product in stock does not match thedimensions required by the customer, an employee/operator will size astock size mini-blind product to the customer's specified dimension.This system only requires that the operator select the stock mini-blindproduct having a width greater than that required by the customer. Theoperator, as will be described herein, does not need to calculate thedifference between the stock product and customer's dimensions, nor doesthe operator need to divide the difference between the stock mini-blindproduct and the customer's specifications. The operator will cut aportion of the head rail, bottom rail and window covering material fromeach end of the stock mini-blind product, without the need to know anyvalue but the customer's desired end width of the mini-blind. Byremoving material from both ends of the mini-blind product as describedbelow, each pair of lift cords will remain an equal distance from eachrespective end of the mini-blind.

Once the operator has identified and selected the stock mini-blindproduct closest to, yet wider than the customer's specification, thecutting center 10 is pulled from the stored position in bay 14 asillustrated in FIG. 1 to the extended position as illustrated in FIG. 2.The operator gains access to the center controls by entering a passwordinto the center access panel 196 of the control mechanism 22. Thecontrol mechanism 22 may be connected to a computer that identifies theoperator seeking access to the cutting center 10. The computer may alsostore the information entered by the operator including the time ofentry. The system may further be programmed to allow the operator toenter information relative to the stock blind being sized as a way ofmonitoring inventory. Additionally, the time required to size themini-blind may be recorded. The access panel 196 has the added benefitof prohibiting unauthorized personnel from accessing the cutting center10.

After the cutting center 10 has been activated by means of the accesspanel 196, the operator loads the stock mini-blind product onto the topworking surface 36. As discussed above, both the pin locator and centralclip locator for centrally locating the stock mini-blind to be sized maybe utilized. For illustration purposes only, the pin locator will bedescribed for locating the mini-blind product relative to the firstcutting station 16 and the center clip locator will be described forlocating the wooden mini-blind product relative to the second cuttingstation 18. However, the center clip locator could be used to locate themini-blind product relative to the first cutting station as well.

When using the pin locator, the bottom rail of each stock mini-blindproduct includes a centrally located aperture or opening through thebottom most portion of the bottom rail. The aperture could also be aslot extending perpendicular to the longitudinal axis of the bottomrail, or an indentation or depression or connector or any other meansfor centrally locating the mini-blind product. The aperture is centrallylocated in the bottom rail, however, the aperture or locating meanscould also be located in the head rail. The operator locates theaperture onto pin 62 of the pin locator 48. The portions of the firstend of the head rail, bottom rail and slats that are to be cut off areslid through the first regions 114, 142 of the stationary and movabledies 104, 106. The bottom rail is located in channel 116 of thestationary die 104 and opening 144 of the movable die 106. Similarly,the slats are located in opening 118 of the stationary die 104 andopening 144 of the movable die 106. Finally, the head rail is located inchannel 120 of the stationary die 104 and opening 164 of the movable die106.

The stock mini-blind product is positioned relative to the cutting plane88 of the first cutting center 16 by lining up pointer 68 of the pinlocator 48 with the customer's specification on the half scale indiciaon first scale 70. The half scale indicia is dimensioned relative to thecutting plane 88 of the first cutting station 16 which is generallydefined by the outer surface of the stationary die 104 that determinesthe location of the sized end of the head rail, bottom rail and slatsafter the movable die 106 is activated and shears and/or cuts the headrail, bottom rail and slats. The half scale units are one half of theactual distance from the cutting plane. For example thirty (30) incheson the half scale is only one half of thirty (30) or actually onlyfifteen (15) inches from the cutting plane. Once the movable die 106 isactivated the newly cut ends of head rail, bottom rail and slats will be15 inches from the center aperture.

To activate the movable die 106 in the first cutting station 16, theoperator turns on the first cutting station 16 with an on/off switchlocated on the controller 22. By simultaneously depressing the twoactivation buttons, the movable die 106 is moved from the rest positionto the extended position by a plunger 198 that is driven by a pneumaticor hydraulic cylinder 200. The first blade 146 shears the slats andsubsequently the bottom rail, while the shear portion of opening 148shears the head rail. If the operator releases the activation buttonsduring the cutting process, the movable die 106 will stop. This featureensures that the operator's hands are safely away from the movable die106 during the activation sequence. Once the movable die 106 is fullyextended and the first end of the head rail, bottom rail and slats aresized, the movable die 106 retracts to the rest position.

After the first side of the mini-blind product is sized, the operatorremoves the mini-blind product from pin 62 and rotates it such that thesized end of the mini-blind product is away from the first cuttingstation 16. The center aperture on the bottom rail of the mini-blindproduct is once again located on pin 62. Once the mini-blind has beenlocated, the movable die 106 is activated and the second side of thehead rail, bottom rail and slats are sized. In this example the desiredwidth of the mini-blind product was thirty (30) inches. Since each sideof the blind was sized relative to the central locating hole in thebottom rail, the cut ends of the mini-blind product are fifteen (15)inches from the center for a total mini-blind width of thirty (30)inches. In this manner the lift cords are equal distance from the centerof the mini-blind product and equal distance to their respective ends ofthe sized mini-blind product.

The sizing of the metal mini-blind occurs while the first cuttingstation 16 is in the first position relative to housing 20 as describedabove. A vinyl mini-blind is sized in a second position of the cuttingstation. To move the first cutting station 16 to the second positionutilizing the hydraulic piston, the operator utilizes the controller 22to move the first cutting station 16 to the second position. In thealternative embodiment, the manual release mechanism 186 may be used tomove the frame. The buttons 188 of the release mechanism are pulledoutward releasing the pins 192 from the support members 194 therebypermitting the operator to move the first cutting station 16 upwarduntil the buttons are aligned with and engaged with a second pair ofsupport members 194. The steps for sizing the vinyl mini-blind in thefirst cutting station are the same as the steps for sizing the metalmini-blind as described above. However, the vinyl mini-blind is sized inthe second regions 122, 152 of the stationary and movable the 104, 106.

The process of sizing a pleated or cellular shade will now be described.The pleated material is sized independently of the bottom rail and headrail. The shearing portions 168, 170 of the third portion 162 of movabledie 106 that are used to size the bottom rail and head rail of a pleatedshade are not sharp enough to cleanly cut the material. The pleatedmaterial is sized in a separate step from the sizing of the head railand bottom rail utilizing a sharp blade 174. In a pleated blind the liftcords are visible and therefore it is desirable to have the pair of liftcords be symmetrical with respect to the center of the pleated blind.Accordingly, the pleated blind may be sized in four distinct steps.First one end of the head rail and bottom rail are sized to the finalwidth of the pleated shade. Second, one end of the pleated material issized. Third, the other end of the head rail and bottom rail is sized.Fourth, the other end of the pleated material is sized.

The steps for removing the cutting center 10 from the bay 14, andaccessing the cutting center 10 is the same as that described above forsizing the mini-blind products. Additionally, the first cutting station16 is moved to the first position to size the pleated shade product.This is the same position as when the metal mini-blind product is beingsized.

As with the mini-blind products discussed above, the bottom rail of thepleated shade includes an aperture which is located on pin 64 of pinlocator 48. In contrast to the front pin 62 utilized to locate themini-blind product s, the rear pin 64 is utilized to locate the pleatedor cellular shade. By using the half scale indicia of the first scale70, the pin locator 48 is aligned with the finished dimension of thecustomer's specification.

The first end of the head rail and bottom rail are slid into channels132, 134 respectively and openings 164, 166 of the movable die 106. Thepleated material however, is not slid into any opening at this time, butrather the pleated material is slid relative to the bottom rail and headrail, so that one end of the pleated material extends past the secondend of the head rail and bottom rail. The first cutting station 16 isactivated as discussed above with respect to the mini-blind products.

After the first ends of the pleated head rail and bottom rail are sized,the pleated material is slid into openings channels 132, 134 of thestationary die 104 and openings 164, 166 of the movable die 106. Thedimension of the guide die plate 108 proximate opening 140 does notpermit the head rail and bottom rails to pass into opening 140 and isstopped a predetermined distance from the cutting plane. In thepreferred embodiment, the distance from the ends is one inch. The endlocator is used to size the pleated material. The end locator set block100 received between the pleated shade bottom rail and head rail suchthat the set block 100 pushes the pleated material forward the sized endof the bottom rail and head rail a predetermined distance. In thepreferred embodiment the set block extends one inch from the first sideof the end locator extension to compensate for the one inch distance thebottom rail and head rails are short of the cutting plane 88. In thismanner when the pleated material is sized by blade 174 the width of thepleated material is the same as the width of the head rail and bottomrail.

The process is repeated on the second ends of the pleated shade headrail, bottom rail and pleated material. Where the head rail and bottomrail are not symmetric the second ends of the head rail and bottom railwill not fit in channels 132, 134. The second ends of the head rail andbottom rail must be inserted into channels 136, 138 respectively, thatare configured to accommodate the different orientation of the secondends of the pleated shade bottom rail and head rail.

Alternatively, the stock pleated shade product may be sized in threesteps. First the head rail and bottom rail may be sized by cuttingmaterial off from a single end to the final width of the customer'sspecification. Since the head rail and bottom rail are being sized fromone end only, a full scale may be utilized to locate the head rail andbottom rail relative to the cutting plane. The pleated material is thencut equally on both sides in two separate cutting operations so that thelift cords remain symmetric about the center of the head rail and bottomrail.

Referring to FIGS. 25 and 26, the sizing of the cellular product in twosteps is illustrated. In the first step the entire portion to be removedfrom the stock cellular head rail and bottom rail is removed in a singleoperation of the movable die 106 (FIG. 8). Accordingly, the cellularshade may be located relative to a cellular scale 202 having full scaleindicia such that the markings on the scale 202 (FIG. 4) reflects theactual distance from the cutting plane 88. The end locator 52 isutilized to locate the cellular product to be sized. The head rail andbottom rail of the cellular product are inserted into channels 132, 134(FIG. 8) while the other ends of the head rail and bottom rail that arenot to be sized are located against the first side of the end locator52. The first side of the end locator 52 is aligned with the full scaleindicia of scale 202 corresponding to the actual width of the blind asrequested by the customer. When the head rail and bottom rail are beingsized the cellular material is slid away from the ends of the blind tobe cut off and towards the second cutting station 18. The cellularmaterial is allowed to pass through end locator 52 extension 94 viaopening 102.

Once the head rail and bottom rail have been cut to size, the cellularmaterial is slid past the newly cut ends of the head rail and bottomrail into openings 140 and 172 of the stationary and movable dies 104,106 (FIGS. 8, 9) respectively. The end locator set block 100 pushes thecellular material the required distance into the first cutting stationto ensure that the cellular material will have the same width as thehead rail and bottom rail once it is sized. The set block 100 isutilized the same way for the cellular material as for the pleatedmaterial discussed above.

Referring to FIGS. 12-16 the second cutting station 18 includes avertical head rail shearing mechanism 204 and a wooden blind sizingmechanism 206. Vertical shearing mechanism 204 includes a stationary die208 having a channel 210 for receiving a head rail of a vertical blindproduct. The stationary die 208 includes a second opening 211 forreceiving the traverse rod of the vertical blind product. A movable die212 moves relative to the stationary die 208 in a vertical up/downdirection. Movable die 212 includes a shearing portion 214.Additionally, vertical shearing mechanism 204 includes a punch 216 thatpunches a hole in the base of the vertical blind head rail a setdistance from the cut end of the head rail as described below. Avertically oriented piston 217 moves the movable die 212 upward anddownward as illustrated in FIGS. 13 and 14 respectively.

Turning to FIGS. 12, 15 and 16, the wooden blind sizing mechanism 206includes a circular saw 218 having a circular blade 220 that moves froma first position proximate the rear wall 34 to an extended position inthe cross housing direction toward the front wall 28.

The sizing of a wooden blind having a metal head rail, a wooden bottomrail and wooden slats will now be described. While a pin locator 48could be used to locate the wooden blind for sizing, the center cliplocator 50 will be described in connection with the sizing of the woodenblind. As illustrated in FIGS. 22 and 23, a head rail includes anopening 86 that receives a protrusion or tab extending from clip 80. Inthis manner the clip is positively located on the center of the headrail 82. The clip 80 is then positioned within slot 78 of the centerclip locator 50, which positions the clip and the head rail relative tothe second half scale 76. A pointer 74 on the center clip locatoridentifies the center position of the wooden blind to be sized relativeto the cutting plane 92 of the circular saw 218.

Once the head rail and clip are located within the slot of the centerclip locator, the wooden blind bottom rail, slats and head rail are slidinto a first opening 221 in the second cutting station (See FIG. 28).The wooden blind is located by moving the center clip locator 50 toalign the pointer 74 of the center slat locator with the customer'swidth specification on the second scale 76.

Once the wooden mini-blind is at the proper location to be sized, theend locator 52 is used to square the ends of the head rail, slats andbottom rail, by using the second side extension second side 98. A clampmechanism 222 clamps the bottom rail, the wooden slats and the head railagainst a stop 224 (See FIG. 29) such that the sides of the rails andslats are parallel to the top working surface 36. This removes any spacedistance between the slats, the bottom rail and the head rail.

Once the bottom rail, slats and head rail have been located within theopening 221 and clamped against the stop 224, the first end of thewooden mini-blind is ready to be sized. As with the first cuttingstation 16, the operator first enters the access code in the centeraccess panel 22 to allow activation of the second cutting station 18. Toactivate the sequence for sizing the wooden blind bottom rail, slats andmetal head rail, the operator turns on the second cutting station 18with the on/off switch. By simultaneously depressing two activationbuttons, the following sequence is activated. First the vacuum 46 isstarted and the circular saw 218 is activated and moved toward the frontwall 28 along cutting plane 92 cutting the bottom rail, slats and headrail until the bottom rail, all of the slats, and the head rail are eachsized. The circular saw 218 is then moved rearward until it is in itsfully withdrawn position. In the preferred embodiment the movement ofthe saw is automated and controlled by the controller 22.

In addition to wooden slats, the circular saw 218 may also size fauxwood slats made of a cellulose plastic formulation or of slats made froma plastic material, or any other type of material that can effectivelybe sized with a circular saw. The circular saw 218 includes a circularsaw blade 220 that travels along a cutting path 92.

It is also possible to size a valance for the wooden blind at the sametime the head rail, bottom rail and slats are being sized. The valanceis simply located adjacent the head rail or bottom rail and sized alongwith the other components.

A vertical blind may also be sized in the second cutting station 18. Avertical blind head rail is sized in the vertical shearing mechanism 204by locating the vertical blind head rail in the vertical blind head railchannel 210. The vertical blind traverse rod is located within thetraverse rod opening 211. Since the vertical blind does not include liftcords, the vertical blind head rail may be sized by removing materialfrom a single side of the stock head rail. Accordingly, a scale 225(FIG. 4) having full scale indicia are used to determine the width ofthe vertical blind. Again, the width of the vertical blind is measuredto correspond to the width of the window it will be covering. Thecutting plane of the vertical shearing mechanism 204 is not in the sameplane as the cutting plane 92 of the circular saw. The vertical shearingmechanism is set inward in the housing to permit the circular saw tofully extend along its cutting plane 92 without contacting the shearingmechanism. The scale 225 measures the actual distance to the cuttingplane of the vertical shearing mechanism 204.

The vertical shearing mechanism 204 also includes a punch 216 to placean aperture in the base of the vertical head rail a set distance fromthe cutting plane of the vertical shearing mechanism 204. The apertureis located a predetermined distance from the cut end of the head rail toreceive a portion of a snap-in end cap to be added to the vertical headrail once it has been sized. The aperture could also be used to receivea fastener such as a screw to secure an end cap to the head rail. Punch216 is pivotally connected to a lever 228 that is pivotally connected tothe vertical shearing mechanism 204. The lever 228 is pivotallyconnected to a head portion 230 of a rod 232 which is slidably locatedin a holder 234 attached to the movable die 212. The head portion 230includes a base portion having a diameter larger than the rod 232 andlarger than the opening in the holder 234.

The operation of the vertical shearing mechanism 204 for sizing thevertical blind head rail will now be described. Since the vertical blindhead rail can be sized by removing material on one side of the headrail, no centering locating mechanism need be used. Rather, the verticalblind head rail can be measured by use of the full scale indicia onscale 225. The end of the vertical blind head rail to be cut is placedin channel 210 and the traverse rod is placed in opening 211. The freeend of the head rail that is not being sized is aligned with the fullscale indicia indicating the customer's specification for the desiredwidth of the vertical blind product. The vertical slats will be sized toa different measurement, since the important feature of the verticalslats is their vertical length when they are placed over a window. Oncethe vertical blind head rail and traverse rod are located in thestationary die 208 the operator activates the shearing mechanism byfollowing the steps outlined above of inputting the access code, turningthe on/off switch to the on position for the second machine cutter, anddepressing the two activation buttons.

The movable die 212 will move in an upward direction until the “v”shaped shearing portion 214 contacts and shears the vertical head railand the traverse rod. Once the holder contacts the base of the headportion 230, the head portion is moved upward, thereby causing the pivotof lever 228 about its pivot point and causing the punch 216 to extenddownwards through the head rail. In this manner, an opening is formed inthe vertical head rail a predetermined distance from the sheared end ofthe vertical head rail.

Once the movable die has reached its fully extended upward position andthe head rail and traverse rod have been sheared and the opening hasbeen punched in the head rail, the movable die is retracted downward tothe starting position. The vertical blind slats may also be sized in thesecond cutting station 18 to a customer's specifications. The verticalslats extend in a vertical position and therefore are likely to have adimension different than the head rail width. The vertical slats areclamped down onto top working surface 36 with a vertical clamp 236 (SeeFIG. 30) such that the face of the vertical slats are parallel to thetop working surface 36. If the vertical blind head rail is longer thanthe space between the first and second cutting stations 16, 18, thefirst cutting station 16 may be lowered to a third position as discussedabove to allow the vertical head rail to rest horizontally on the topworking surface 36. When the first cutting station 16 is lowered to thethird position, the top of the frame 178 is substantially flush with orlower than the top working surface. The scale extension 180 is locatedin housing 20 and extends the full scale 226 (FIG. 4) that measures theactual distance to the cutting plane 92.

Unlike the wooden mini-blind product in which the bottom rail, slats andhead rail are all positioned relative to the second cutting stationtogether, the vertical head rail and vertical slats are positioned andsized separately.

In another embodiment, each scale is used for sizing a specific blind orshade product. Further, each scale may have a separate distinct colorthat corresponds with the color of the packaging for respective blind orshade product to be sized. As a result, an operator will be able todetermine which scale to use to size the stock blind or shade product bymatching the color of the stock blind or shade packaging with theappropriate scale. The instructions that are located on the housing mayalso be in color to further reduce the chance that the particular stockblind or shade product is sized incorrectly. Additionally, theinstructions that are located in an instruction manual may also be colorcoordinated with the scale and stock product packaging. Since the scale,packaging for the blind or shade product and instructions all share thesame color for sizing of a specific product, the chance of errordecreases, resulting in an easier process for the operator.

In a further embodiment, the locator pin may be eliminated. The blind orshade product may include a mark or feature that is located on itslongitudinal center. This mark or feature would be aligned with theappropriate marking on the appropriate scale as discussed above. Whilethe locator devices provide for a positive placement of the blind orshade product, it is possible to locate the center of the blind or shadeproduct by means of a mark such as a line placed on the product in thefactory before being shipped to the retain outlet. Of course the markcould also be placed by the operator in the retail outlet as well priorto sizing.

The stock blind or shade product would also have a feature such as anindentation, groove or protrusion on the center of the blind that couldbe used to locate the stock blind or shade product relative to thescale.

While the detailed drawings, specific examples and particularformulations given describe exemplary embodiments, they serve thepurpose of illustration only. The systems shown and described are notlimited to the precise details and conditions disclosed. Furthermore,other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the exemplaryembodiments without departing from the scope of the invention asexpressed in the appended claims.

1. An apparatus for sizing a window covering in a retail outlet, theapparatus comprising: a housing having a first end and a second end, anda fixed top operating surface adapted to support a window covering to besized; and a first cutting station disposed at the first end of thehousing and including a stationary die and a movable die, the stationarydie and the movable die adapted to receive and size a window covering,the stationary die further having a top portion and being downwardlymovable relative to the top operating surface from a first operatingposition to size a window in which the top portion is above the topoperating surface to a retracted position in which the top portion issubstantially flush with or lower than the top operating surface.
 2. Theapparatus of claim 1, further including an extension device thatattaches to the cutting station when positioned in the second retractedposition.
 3. The apparatus of claim 1, further including a secondcutting station proximate the second end having a second die assemblyreceiving a portion of a second window covering head rail to be sheared,and a saw assembly including a saw blade extending along a cutting pathsawing a portion of slats of the second window covering.
 4. Theapparatus of claim 3, wherein, the second die assembly is positioned ina fixed shearing position outside the cutting path.
 5. The apparatus ofclaim 3, wherein, the saw blade is a circular saw blade and movablealong the cutting path from a first start position to a second extendedposition.
 6. The apparatus of claim 5, further including a vacuumcollecting dust resulting from the sawing of the slats.
 7. The apparatusof claim 6, further including a clamp securing the slats to the topoperating surface.
 8. The apparatus of claim 7, further including aclamp securing the head rail, slats and bottom rail to the top operatingsurface.
 9. The apparatus of claim 1, wherein the stationary dieincludes a first region adapted to receive a window covering to besized, the first region being proximate the top operating surface whenthe cutting station is in the first operating position.
 10. Theapparatus of claim 9, the stationary die including a second regionadapted to receive a window covering to be sized, the second regionbeing proximate the top operating surface when the cutting station is inthe first operating position.
 11. The apparatus of claim 9, the firstcutting station being upwardly movable to a second operating position.12. The apparatus of claim 11, wherein the stationary die includes asecond region adapted to receive a window covering to be sized, thesecond region being below the first region and being proximate the topoperating surface when the cutting station is in the second operatingposition.
 13. The apparatus of claim 12, the stationary die including athird region adapted to receive a window covering to be sized, the thirdregion being vertically aligned with the first region and beingproximate the top operating surface when the cutting station is in thefirst operating position.
 14. A method of sizing a window covering in aretail outlet, comprising: disposing a first window covering to be sizedon a top of an operating surface of a housing, the housing having afirst end and a second end, a movable first cutting station beingdisposed at the first end and in a first operating position, the firstcutting station including a first stationary die and a second movabledie and having a first region adapted to receive and size a windowcovering; inserting the first window covering in the first region;sizing the window covering; and moving the first cutting stationdownwardly from the first operating position in which a top portion ofthe stationary die is higher than the top operating surface to aretracted position in which the top portion is substantially flush withor lower than the top operating surface.
 15. The method of claim 14,further comprising: removing the first window covering from the topoperating surface after sizing the first window covering; disposing asecond window covering on the top operating surface; inserting thesecond window covering into a second region of the first cuttingstation; and sizing the second window covering.
 16. The method of claim14, further comprising: removing the first window covering from the topoperating surface after sizing the first window covering; moving thefirst cutting station downwardly from the first operating position to asecond operating position in which a second region is proximate the topoperating surface; disposing a second window covering on the topoperating surface; inserting the second window covering into a secondregion of the first cutting station, the second region being below thefirst region; and sizing the second window covering.
 17. The method ofclaim 14, further comprising: inserting a window covering in a secondcutting station disposed on the second end of the housing; laying thesecond window covering on top of the top portion of the first cuttingstation.
 18. The method of claim 17 further comprising: supporting thesecond window covering with an extension device attached to the firstcutting station.
 19. The method of claim 17, wherein the second cuttingstation includes a second stationary die and a second movable die, themethod further comprising sizing the second window covering by movingthe second movable die relative to the second stationary die.
 20. Themethod of claim 17, wherein the second cutting station includes acircular saw, the method further comprising sizing the second windowcovering by causing the circular saw to traverse a cutting path.
 21. Anapparatus for sizing a window covering in a retail outlet, comprising:support means for supporting a window covering to be sized; and cuttingmeans for sizing a window covering, wherein the cutting means aremoveable downwardly from a sizing position in which the cutting means ishither than the support means to a retracted position in which thecutting means is flush with or lower than the support means.
 22. Anapparatus for sizing window covering, comprising: a surface disposed ata cutting elevation and adapted to support a window covering; a firstcutter disposed adjacent the surface and adapted to receive and size awindow covering; a second cutter disposed adjacent the surface and belowthe first cutter and adapted to receive and size a window covering; andwherein the first cutter and the second cutter are vertically movable toand from the cutting elevation to selectively receive and size a windowcovering on the surface.
 23. The apparatus for sizing a window coveringof claim 22, wherein the first cutter is adapted to size a metal blind,and the second cutter is adapted to size a vinyl blind.
 24. Theapparatus for sizing a window covering of claim 22, wherein the firstcutter is defined by a region in a stationary die and a movable die. 25.The apparatus for sizing a window covering of claim 24, wherein thesecond cutter is defined by a second region in the stationary die andthe movable die.
 26. An apparatus for sizing a window covering in aretail outlet, the apparatus comprising: a housing having a first endand a second end, and a top operating surface adapted to support awindow covering to be sized; and a first cutting station disposed at thefirst end of the housing and including a first region adapted to receiveand size a first window covering and a second region above the firstregion, the second region adapted to receive and size a second windowcovering; wherein the first cutting station is moveable independent ofthe top operating surface in a generally downward direction from a firstposition in which the first region is proximate the top operatingsurface to a second position in which the second region is proximate thetop operating surface.
 27. The apparatus of claim 26, wherein the firstcutting station is moveable generally vertically upward and downward.28. The apparatus of claim 1, wherein the first cutting station ismoveable independently of the top operating surface.
 29. The apparatusof claim 1, wherein the first cutting station is moveable generallyvertically upward and downward.